Cushioning conversion machine and method

A method for making a cushioning product by converting an essentially two-dimensional web of sheet stock material of at least one ply into a three-dimensional cushioning product, including the steps of:

• supplying the stock material;
• using an upstream component of a feeding/connecting assembly to advance the stock material toward a downstream component of the feeding/connecting assembly at a rate faster than the stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form a strip of cushioning;
• and
• varying the ratio of the feeding speeds of the upstream and downstream feeding components, whereby the density of the strip of cushioning can be varied;
• wherein said varying step is accomplished by an accessible control member outside a housing through which the stock material passes along a path thereby enabling operator adjustment of the ratio.

A cushioning conversion machine for making a cushioning product by converting an essentially two-dimensional web of sheet stock material of at least one ply into a relatively lower density three-dimensional cushioning product, comprising:

• a feeding/connecting assembly which advances the stock material from a source thereof along a path, crumples the stock material, and connects the crumpled stock material to produce a strip of cushioning, said feeding/connecting assembly including:
• upstream and downstream feeding components disposed along said path, the upstream feeding component being driven to advance the stock material toward the downstream component at a rate faster than the stock material can pass from the downstream component to effect crumpling of the stock material therebetween to form the strip of cushioning;
• and
• an adjustable speed control mechanism for varying the ratio of the feeding speeds of the upstream and downstream feeding components, whereby the density of the strip of cushioning can be varied selectively.